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Allied Reliability




Introduction to
Allied Reliability




                        What would you
                     ...
Allied Reliability

About Allied Reliability, Inc.
• Founded in 1997 as Allied Services Group
   – Reliability consulting ...
Allied Reliability

Allied’s Mission Statement
• To be the Reliability Supplier of Choice to the marketplace and the
  Emp...
Allied Reliability




                     Copyright 2009 Allied Reliability, Inc.
Allied Reliability




Allied Reliability
                                                                                ...
Allied Reliability

ProActive Work Flow Model




                                   Copyright 2009 Allied Reliability, In...
Al l i e d   Re l i a b i l i t y



Why Allied as a partner in Reliability?
•   The Approach
•   The Proven Track Record
...
Allied Reliability

The Approach
• Integrated collection of Best Practices
• Highly Standardized
  – Personnel Qualificati...
Allied Reliability

Best Practice Benchmarking
“Best Practice Plants have Best Practice Behaviors and those
  behaviors dr...
Allied Reliability

Best Practice Benchmarking, cont.
   “I could agree with you, but then we’d both be wrong”




       ...
Allied Reliability

Maintenance Opportunity

                                                         % OIL % TRAD
       ...
Allied Reliability

Case Study Results
Pharmaceuticals Industry
• Prior to Reliability Initiative
   – Patented product go...
Allied Reliability

Case Study Results, cont’d
Pharmaceuticals Industry
• After Reliability Initiative
   – Availability i...
Allied Reliability

Case Study Results, cont’d
Chemical Processing and Mining
• Increase OEE by nearly 30% in 2 years
  – ...
Allied Reliability

Case Study Results, cont’d
Power Generation
• Successfully extended time between planned
  turnarounds...
Allied Reliability

Available Training Classes
• Asset Health Assurance (PM/PdM Best Practices) Series
   – Overview, Mech...
Allied Reliability

Processes and Tools
•   Based on the collection of Best Practices
•   Built by “Users”
•   Integration...
Allied Reliability

           Asset Health Assurance Model
                                   HOW MUCH                   ...
Allied Reliability

Available Applications
    TEAMTM
•
•   Walkdown Tool
•   Criticality Analysis Tool
•   Asset Health M...
Allied Reliability

Global Reach
• Clients are driving us into the global market
• Strong hubs in the US, Canada, Puerto R...
Allied Reliability

Impact of a Complete Reliability Initiative
      High

                                              ...
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Allied Intro (Short)

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Short Introduction to Allied Reliability

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Allied Intro (Short)

  1. 1. Allied Reliability Introduction to Allied Reliability What would you do with more free time? Copyright 2009 Allied Reliability, Inc.
  2. 2. Allied Reliability About Allied Reliability, Inc. • Founded in 1997 as Allied Services Group – Reliability consulting firm specializing in delivering real business results via predictive maintenance and reliability through: • Implementation • Facilitation • Coaching • Education • Support – Full-service reliability education, consulting, coaching, and technical services delivery – Headquarters in Charleston, South Carolina, USA – Combined staff of over 200 experienced and well trained reliability specialists, reliability engineers, instructors, coaches, technicians, and support personnel – Employees in 40 States and 8 Countries – Offices in Europe, Latin America, Canada and the U.S. – Licensed Partner in Pacific Rim Copyright 2009 Allied Reliability, Inc.
  3. 3. Allied Reliability Allied’s Mission Statement • To be the Reliability Supplier of Choice to the marketplace and the Employer of Choice for people who share our passion to succeed. • We commit to the following: – To listen to our customers so that we may integrate our collection of best practices and standards to meet their unique needs – To make a commitment to safely deliver quality services – To act with integrity and establish trust-based relationships with our customers and employees – To proactively respond to our customers and employees by systematically improving our processes and practices – To make a long-term commitment to our employees that empowers them to be leaders in their area of responsibility – To provide our employees with the opportunities and tools that will enable them to reach their full potential Copyright 2009 Allied Reliability, Inc.
  4. 4. Allied Reliability Copyright 2009 Allied Reliability, Inc.
  5. 5. Allied Reliability Allied Reliability The Market Reliability Ops COE in Maintenance: PM/PdM Optimization, Criticality, Walkdown, Failure Mode Analysis, RCA Reliability Reliability in Operations: in Design: Process Reliability, RCD, DFM, LCC, Innovation LEAN, Six Sigma, RBD, Simulation Modeling RE Stats, ROAR™, Process Modeling Copyright 2009 Allied Reliability, Inc.
  6. 6. Allied Reliability ProActive Work Flow Model Copyright 2009 Allied Reliability, Inc.
  7. 7. Al l i e d Re l i a b i l i t y Why Allied as a partner in Reliability? • The Approach • The Proven Track Record • The Personnel and Training • The Processes and Tools • The Global Reach Copyright 2009 Allied Reliability, Inc.
  8. 8. Allied Reliability The Approach • Integrated collection of Best Practices • Highly Standardized – Personnel Qualifications and Technology Standards • Business Centric • Partnership Model Copyright 2009 Allied Reliability, Inc.
  9. 9. Allied Reliability Best Practice Benchmarking “Best Practice Plants have Best Practice Behaviors and those behaviors drive Best Practice Results” • Focused on 35 Companies that have known corporate reliability initiatives in 8 verticals – Automotive, Chemical Processing, Food & Beverage, Metals & Mining, Petro-Chemical, Pharmaceutical, Power Generation/Transmission Pulp & Paper • Focused on 35 Best Practice Elements Across 4 Primary Areas – Leadership – Work Management – Reliability Engineering – Asset Health Management • Results represent performance at 633 sites in over 20 countries • Additional 250 sites in overall database Copyright 2009 Allied Reliability, Inc.
  10. 10. Allied Reliability Best Practice Benchmarking, cont. “I could agree with you, but then we’d both be wrong” Industry Vertical Overall Average Chemical Processing 523.0 Petro 497.0 Pulp & Paper 470.0 Automotive 467.0 Pharmaceutical 432.0 Metals & Mining 431.0 Power Generation 372.0 Food & Beverage 371.0 Copyright 2009 Allied Reliability, Inc.
  11. 11. Allied Reliability Maintenance Opportunity % OIL % TRAD MAINT $ STORES $ % IR % IR % ON % ON % ANALYSIS NDT QUARTILE % RAV % RAV ELEC MECH PM BOM VIBE Top 1st 1.4% 0.3% 88.5% 71.0% 100.0% 38.1% 51.0% 20.0% 71.0% Middle 1st 3.1% 0.6% 78.0% 60.9% 91.0% 35.7% 42.0% 23.0% 65.0% Top 2nd 4.1% 0.8% 60.0% 51.7% 85.6% 29.8% 36.1% 24.0% 59.0% Middle 2nd 5.7% 1.7% 51.2% 41.2% 83.0% 24.3% 29.8% 27.0% 55.0% Top 3rd 7.1% 2.9% 44.4% 34.6% 79.8% 19.8% 22.9% 28.0% 50.0% Middle 3rd 8.9% 4.1% 29.3% 21.2% 69.8% 15.4% 18.7% 31.0% 45.0% Top 4th 10.8% 5.4% 19.8% 15.0% 63.8% 10.8% 13.7% 35.0% 41.0% Middle 4th 13.7% 7.4% 9.3% 3.6% 56.7% 5.1% 8.9% 37.0% 36.0% Bottom 4th 17.3% 12.2% 2.9% 0.0% 48.7% 1.0% 4.1% 39.0% 28.0% Copyright 2009 Allied Reliability, Inc.
  12. 12. Allied Reliability Case Study Results Pharmaceuticals Industry • Prior to Reliability Initiative – Patented product going off patent • After Reliability Initiative – Reactive Maintenance 71% 7% – Overtime 22% 5% – Maintenance Employees (FTEs) 350 250 – Added 9 Planners, 7 PdM Technicians and 8 Reliability Engineers… Source: John Schultz Copyright 2009 Allied Reliability, Inc.
  13. 13. Allied Reliability Case Study Results, cont’d Pharmaceuticals Industry • After Reliability Initiative – Availability increased 12% – Healthy Assets 35% 85% – Production Deviations to 1/10th of previous levels – Maintenance Budget reduced 40% – Inventory reduced 33% – Insurance Premiums reduced 30% Source: John Schultz Copyright 2009 Allied Reliability, Inc.
  14. 14. Allied Reliability Case Study Results, cont’d Chemical Processing and Mining • Increase OEE by nearly 30% in 2 years – 22% reduction in their annual maintenance expenditure – $15 million per year on the bottom line Source: Mosaic Corporation Copyright 2009 Allied Reliability, Inc.
  15. 15. Allied Reliability Case Study Results, cont’d Power Generation • Successfully extended time between planned turnarounds by 30% – Reduce time in turnaround by 20% – 23% reduction in maintenance costs Source: Alliant Energy Copyright 2009 Allied Reliability, Inc.
  16. 16. Allied Reliability Available Training Classes • Asset Health Assurance (PM/PdM Best Practices) Series – Overview, Mechanical, Electrical, Stationary • Reliability Engineering Series – Reliability Engineering Fundamentals, Reliability Statistics, Life Cycle Cost Analysis, Root Cause Analysis, Reliability Centered Maintenance, Condition Monitoring • Asset Health Assurance by Design • Transformational AnalyticsTM • ROAR™ (Return On Asset Reliability) • Introduction to PM/PdM • Developing Effective Work Procedures • Customized Training Solutions Available Copyright 2009 Allied Reliability, Inc.
  17. 17. Allied Reliability Processes and Tools • Based on the collection of Best Practices • Built by “Users” • Integration Theme • Enforces Discipline to Standards • Drives Transparency Copyright 2009 Allied Reliability, Inc.
  18. 18. Allied Reliability Asset Health Assurance Model HOW MUCH HOW WELL Enabling Tools Asset OP-1 & PM/PdM Walkdown Criticality TEAMTM Health OP-2 BP Tool Tool Matrix Tool Standards Tool Process Check Failure Asset Asset Criticality Corporate Maturity Modes Health Catalog Analysis Standards Spider Analysis Report Compliance Check Meets Meets Meets Meets Meets Y Y Y Y Y Minimum Minimum Minimum Minimum Minimum Proactive Standard Standard Standard Standard Standard Workflow Model N N N N N Result of non-compliance Cannot Report Asset Health Copyright 2009 Allied Reliability, Inc.
  19. 19. Allied Reliability Available Applications TEAMTM • • Walkdown Tool • Criticality Analysis Tool • Asset Health Matrix Tool • Preventive Maintenance Evaluation Tool • EMP Management Tool RCM BlitzTM • • Procedure Development Tool • Custom applications can be built for specific client needs Copyright 2009 Allied Reliability, Inc.
  20. 20. Allied Reliability Global Reach • Clients are driving us into the global market • Strong hubs in the US, Canada, Puerto Rico, and Western Europe exist • Signed MOU to form a Joint Venture with General Physics – Established operations beyond current reach in: • Asia – China, India, South Korea, Japan, Malaysia • Latin America – Brazil and Mexico – Additional Critical Offerings • Operational Excellence, Maintenance Excellence, Leadership Development, Remote Monitoring, Craft Skills, Operator Care, and Plant Launch Copyright 2009 Allied Reliability, Inc.
  21. 21. Allied Reliability Impact of a Complete Reliability Initiative High +75% +27% • Significantly Improved • Improved Bottom Bottom Line Line Performance Business Process and Performance Culture Maturity • Lack of System • Practices and Systems Support Aligned Baseline -7% • Systems are not •Informal Complemented by Effective • Manual Planning Business Processes Processes • Significant Inefficiencies • Below Average Business Performance Low High Low Technology Maturity Source: Brynjolfsson (MIT), Wireman, Troyer, Allied Copyright 2009 Allied Reliability, Inc.

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